Isoparaffin-olefin alkylation utilizing fluorosulfonic acid and sulfuric acid catalyst

ABSTRACT

A liquid phase alkylation process for production of alkylate useful as motor fuel, wherein low molecular weight isoparaffin hydrocarbons are alkylated with olefin hydrocarbons in the presence of a catalyst comprising HFSO3 and H2SO4 in weight ratio of from about 0.11 to 1 to about 0.32 to 1, respectively, having a titratable acidity in the range of 16.5 to 21 milliequivalents per gram, and which may contain about 0-3 weight percent water and about 0-10 weight percent acid oils.

United States Patent [1 1 Brockington Nov. 25, 1975 [75] Inventor: James W. Brockington, Richmond,

[73] Assignee: Texaco Inc., New York, NY.

[22] Filed: Nov. 4, 1974 [21] Appl. No.: 520,595

[52] US. Cl. 260/683.63 [51] Int. Cl. C07C 3/54 [58] Field of Search 260/683.63, 683.59, 683.58

[56] References Cited UNITED STATES PATENTS 2,425,572 8/l947 Slotterbeck 260/683.63

323L633 l/l966 Kramer 260/683.63

Primary E.\(mzinerDelbert E. Gantz Assistant E.\'aminerG. J. Crasanakis Attorney, Agent, or Firn1T. H. Whaley; C. G. Ries; Douglas H. May, Jr.

[57] ABSTRACT A liquid phase alkylation process for production of alkylate useful as motor fuel, wherein low molecular weight isoparaffin hydrocarbons are alkylated with olefin hydrocarbons in the presence of a catalyst comprising HFSO and H 50 in weight ratio of from about 0.1 l to l to about 0.32 to 1. respectively, having a titratable acidity in the range of 16.5 to 2] milliequivalents per gram, and which may contain about 0-3 weight percent water and about 0-10 weight percent acid oils.

10 Claims, N0 Drawings ISOPARAFFIN-OLEFIN ALKYLATION UTILIZING FLUOROSULFONIC ACID AND SULFURIC ACID CATALYST BACKGROUND OF THE INVENTION 1. FIELD OF THE INVENTION The present invention relates to liquid phase, acid catalyzed alkylation of isoparaffin hydrocarbon with olefine hydrocarbon for production of alkylate having high octane value and being suitable for gasoline blending stock. More particularly, the present invention relates to such an alkylation process wherein improved acid catalysts comprising selected ratios of fluorosulfonic and sulfuric acid are employed.

2. DESCRIPTION OF THE PRIOR ART Liquid phase alkylation processes wherein isoparaffin hydrocarbons, such as isobutane, isopentane, etc. are alkylated with olefin hydrocarbons such as propy lene, butylenes, etc., for production of alkylate products comprising highly branched C C,, range paraffin hydrocarbons having high octane values, are well known and widely practiced. In such alkylation processes, reactant hydrocarbons are generally contacted in the liquid phase, at temperatures in the range of from about OFIOOF, in the presence of acid alkylation catalyst under conditions of good mixing to produce the desired alkylate hydrocarbons. Reaction pressures, which may vary from about ambient to superatmospheric, are sufficient to maintain reactants in the liquid phase. Higher pressures apparently have no substantial effect upon such alkylation reactions. Acid catalysts may be selected from a wide range of strong acids including sulfuric acid and fluorosulfonic acid. Generally, liquid alkylation catalysts such as sulfuric acid and fluorosulfonic acid are substantially immiscible with isoparaffin hydrocarbon reactants. Consequently, reactant hydrocarbons and liquid alkylation catalysts are contacted in an alkylation zone under conditions of high shear mixing sufficient to form an emulsion of immiscible hydrocarbon and catalyst. Detailed description of such alkylation processes is not required herein, as such processes are well known and widely practiced in the prior art.

In such alkylation processes side reactions take place in addition to desired alkylation reactions wherein 1:1 olefin-isoparaffin adducts are produced. For example, olefin hydrocarbons tend to polymerize in the presence of strong acid catalysts to form C and higher molecular weight polymers; also such polymers tend to crack in the presence of the strong acid catalyst forming low octane C C hydrocarbons. These side reaction products, e.g., olefin polymers and cracked products, have relatively low octane values and are not as desirable as the 1:1 olefin isoparaffin alkylation products for use as gasoline blending stocks.

In order to maximize the yield of the desired alkylate products at the expense of the undesired side reaction products, care is taken to insure good contact of isopar affin reactants with olefin reactants in the presence of alkylation catalysts under reaction conditions which favor formation of alkylate hydrocarbon products over side reaction products. For example, reaction temperatures are maintained in the range of about OF to about 100F wherein the alkylation of isoparaffins with olefins proceeds at economically attractive rates and wherein olefin polymerization rates are not so great as to consume excessive amounts of olefin reactant. Further, a substantially stoichiometric excess of isoparaffins over that required to react with olefin is employed to insure contact of isoparaffins with olefins under alkylation reaction conditions. Further, as olefin reactants are generally substantially more soluble in acid catalysts than are isoparaffin reactants, high-shear mixing of the alkylation reaction mixture is generally provided sufficient to form emulsions of acid catalysts and hydrocarbon reactants. Formation of such emulsions increases the contact area between acid catalyst, containing dissolved olefins with isoparaffin hydrocarbons, thus materially improving yield and quality of alkylate product.

Commonly, where sulfuric acid is the selected acid catalyst, the alkylation reaction emulsion is one wherein isoparaffin hydrocarbon is emulsified in a continuous acid phase, although it is known to employ reaction emulsions comprising acid catalyst phase suspended in a continuous isoparaffin hydrocarbon phase. Alkylation reaction mixtures comprising about 407O volume percent sulfuric acid catalyst and about 6030 volume percent hydrocarbon phase are known to form emulsions wherein the acid phase is continuous.

In the prior art, sulfuric and fluorosulfonic acids alone, and mixtures of the two comprising a major portion of fluorosulfonic acid, are known to be effective catalysts for the liquid phase alkylation of isoparaffin hydrocarbons with olefin hydrocarbons. Additionally, US. Pat. No. 2,313,013 claims that alkylation of an isoparaffin with an olefin hydrocarbon employing pure fluorosulfonic acid as catalyst is superior to alkylation employing sulfuric acid catalyst. In US. Pat. No. 3,231,633 it is taught that the catalytic activity of flurosulfonic acid may be improved by the addition of a minor amount of H SO (e.g., not less than 50 weight percent HFSO in the catalyst) thereto. Also, in US. Pat. No. 2,425,572, it is disclosed that the catalytic activity of H 50, may be substantially improved by the addition of about l-l 0% of chlorosulfonic acid or other improved substituted sulfonic acids.

The sulfonic acids, such as fluorosulfonic and chlorosulfonic, are relatively expensive materials compared to sulfuric acid. In alkylation reactions, acid catalyst is consumed at rates ranging from about 0.1 up to 10 and more pounds of catalyst per gallon of alkylate product as a result of side reactions such as hydrolysis and reaction with olefin hydrocarbons. Consequently, the expense of providing sulfonic acids as the major components of alkylation catalysts may become prohibitively expensive in commercial alkylation processes. Both fluorosulfonic and chlorosulfonic acid are known to react with water thereby forming the respective hydrogen halide and H 50 Consequently, alklation processes employing catalysts comprising a major portion of such sulfonic acids must be kept substantially dry in order to prevent destruction of the acid.

SUMMARY OF THE INVENTION Now, according to the present invenetion I have discovered an improved alkylation process wherein C C isoparaffin hydrocarbons are alkylated with C ,C olefin hydrocarbons in the presence of a novel alkylation catalyst comprising fluorosulfonic acid and H 80, in a weight ratio of from about 0.1 l to l to about 0.32 to 1, respectively, having a titratable acidity in the range of 16.5 to 21 milliequivalents per gram (meq/gm), and which may contain about 03 weight percent water and about Ol0 weight percent acid oils In a preferred embodiment, an isoparaffin hydrocarbon such as isobutane is contacted with olefin hydrocarbons such propylene, butylenes, and mixtures thereof in a molar ratio of isoparaffin to olefin of from about 2:1 to :1 in the liquid phase, in the presence of an alkylation catalyst comprising fluorosulfonic acid and H 50, in a weight ratio of 0.17 to l and having a titratable acidity of from about 16.5 to about 18.5 meq/gm. at a temperature in the range from about OF to about 100F for a production of alkylate hydrocarbon product having high octane value and being suitable for use in gasoline motor fuel. Preferably, the alkylation reaction mixture is subjected to good mixing to form a hydrocarbon in continuous acid phase emulsion which comprises from about 40 to about 70 volume percent acid phase and from about 60-30 percent bydrocarbon phase. Residence time of reactant hydrocarbons in the presence of acid catalyst under alkylation reaction conditions is preferably such that olefin space velocity is in the range of about 0.1 to about 1.0 vol- DETAILED DESCRIPTION OF THE INVENTION The improvement of the present invention comprises use of a novel alkylation catalyst in processes for alkylating C C isoparaffin hydrocarbons with C C olefin hydrocarbons for production of high octane alkylate products suitable for use in blending of gasoline motor fuel.

It is well known that sulfuric acid is a particularly effective catalyst for the alkylation of isoparaffin hydrocarbon with olefin hydrocarbon. Additionally, it is known that sulfonic acids, including fluorosulfonic (HFSO chlorosulfonic, and various organic sulfonic acids are effective alkylation catalyst used alone or in admixture with other strong acids such as sulfuric acid. For example, see U.S. Pat. No. 2,259,723, Ballard et al, which teaches the use of chlorosulfonic and fluorosulfonic acids in admixture with hydrogen halides, US. Pat. No. 3,766,293, Parker et a1 whichteaches the use of fluorosulfuric acid in combination with a minor amount of catalyst promoter which may include sulfuric acid; US. Pat. No. 2,231,633, Kramer, which teaches an alkylation process employing fluorosulfonic acid in combination with up to about 50 weight percent sulfuric acid; and US. Pat. No. 2,425,572, Slotterbeck, which teaches an alkylation process wherein a minor portion 1-1070) of chlorosulfonic acid or other substituted sulfonic acids, such as aliphatic sulfonic acids, are added to the sulfuric acid alkylation catalyst. Fluorosulfonic acid, as well as other sulfonic acids, is relatively expensive compared to sulfuric acid. Thus, one of the major disadvantages of using fluorosulfonic acid, or other sulfonic acids, as alkylation catalysts is high cost of these acids. It is disclosed that fluorosulfonic and chlorosulfonic acids are easily hydrolyzed by water into H 80, and the respective hydrogen halide. Consequently, it has been considered desirable, when using these sulfonic acids as major components of alkylation catalyst. to maintain the alkylation system as dry as possible in order to conserve the catalyst. Since many,

or most, commercially available isoparaffinand olefin charge stocks contain water, means must be provided I for drying such charge stock if sulfonic acids are not to be hydrolyzed. Also, where sulfuric acid is to be used as a minor component, commercially available concentrated sulfuric acid of 99.5 to 98 weight percentH SO must be dried or converted to oleum by addition of 5 S0 Surprisingly, we have discovered an alkylation preferably in a weight ratio of about 0.17 to 1. Such catalyst has titratrable acidity of from about 16.5 to about 21 milliequivalents per gram (meq/gm) and may contain from about Oto about 3 wt.% water and from about 0 to about 10 wt.% acid oils. The acid oils are relatively high molecular weight reaction products of sulfuric acid with hydrocarbons present in the alkylation process. The titratable acidity of catalysts in the present invention is determined by titrating a sample of catalyst with a standard aqueous solution of a base, such as sot dium hydroxide, to neutralize the acid, and subse-. quently calculating the molecular equivalents of base required. A catalyst having titratable acidity below about 16.5 (meq/gm), alkylation catalyst activity decreases and the rate of undesirable olefin polymerization reactions increase.

For the acid catalyst of the present invention, we i have discovered that the ratio of sulfuric acid to fluorosulfonic acid is critical for obtaining high octane alkylate.That is, a weight ratio of from about 0.11 to l to about 0.32 to l fluorosulfonic to sulfuric acid, and preferably about 0.17 to 1 weight ratio of fluorosulfonic to,

sulfuric acid provides alkylate of higher octane than catalyst compositions containing either more or less fluorosulfonic acid. That is, a peak, or maximum, in alkylate product octane value occurs when using a catalyst having the preferred weight ratio of fluorosulfonic acid to sulfuric acid. This result is most unexpected and provides a particular advantage as alkylate with maxi- I I mum octane value is obtained employing catalyst havimproved catalyst of the present invention, acid consumption per barrel of alkylate product is also reduced over acid consumption employing sulfuric acid alone.

Therefore, total catalyst cost per barrel of alleylate product may be below. acid catalyst costemploying m only sulfuric acid.

The acid catalyst of this invention may contain from about 1 to about 3% water without being seriously Cleactivated. This is unexpected since it is well known that fluorosulfonic acid ishy drolyzed by cold water and rapidly decomposes. Efforts to form a similar catalyst to i the catalyst of the invention employing chlorosulfonicI acid were unsuccessful because the chlorosulfonic acid reacted rapidly, evolving hydrogen chloride vapors, with water contained in the 98 percent commercial sulfuric acid used. The catalytic activity of the resulting mixture of sulfuric acid and chlorosulfonic acid was substantially below the catalytic activity of the catalyst of the present invention. As the catalyst of the present invention may contain substantial amounts of water without seriously affecting catalytic activity, it is possible to formulate such fresh catalysts employing commercially available sulfuric acid of about 99.5-98 weight percent H 50 concentration and containing up to 2% water.

Fluorosulfonic acid, having the chemical formula HFSO which may be used in thepractice of the present invention need not be completely pure. Commercial grades of fluorosulfonic acid having purities of about 99 percent may be used to formulate the catalysts of the present invention.

Sulfuric acid which is useful in formulating the fresh catalyst of the present invention is concentrated sulfuric acid, preferably of about 99.5-98 weight percent H 50, and containing about O.52 weight percent water.

Alkylation processes contemplated in the present invention are those liquid phase processes wherein isoparaffin hydrocarbons such as isobutane, isopentane, isohexane, etc. are alkylated with monoolefin hydrocarbons such as propylene, butylenes, pentylenes, etc. for production of high octane alkylate hydrocarbons boiling in the gasoline range and which are suitable for use in gasoline motor fuel. Preferably, isobutane is selected as the isoparaffin reactant and olefin reactant is selected from propylene, butylenes, and mixtures thereof for production of an alkylate hydrocarbon product comprising a major portion of highly branched aliphatic C hydrocarbons having high octane value. Such olefin reactants in the presence of strong acids and particularly sulfuric acid, tend to undergo undesirable side reactions such as polymerization as well as desirable alkylation reactions with isoparaffin hydrocarbons. In order to increase selectivity of olefin hydrocarbon conversion for alkylation with isoparaffin hydrocarbon, a substantial stoichiometric excess of isoparaffin hydrocarbon is desirable in the reaction zone. Liquid volume ratios of isoparaffin hydrocarbon to olefin hydrocarbon of from about 2 to l to about to l are contemplated in the present invention. Isoparaffin and olefin reactant hydrocarbons normally employed in commercial alkylation processes are derived from refinery process streams and usually contain small amounts of impurities such as normal butane, propane, etc. Such impurities are undesirable in large concenetration as they dilute reactants in the reaction zone, thus decreasing reactor capacity available for the de sired reactants and interferring with good contact of isoparaffin with olefin reactants. Additionally, in continuous alkylation processes wherein excess isoparaffin hydrocarbon is recovered from an alkylation reaction effluent and recycled for contact with additional olefin hydrocarbon, such nonreactive normal paraffin impurities tend to accumulate in the alkylation system. Consequently, process charge streams and/or recycle streams which contain substantial amounts of normal paraffin impurities are usually fractionated to remove such impurities and maintain their concentration at a low level, preferably less then about 5%, in the alkylation process.

Alkylation reaction temperatures within the contemplation of the present invention are in the range of from about OF to about 100F. Lower temperatures favor alkylation reactions of isoparaffin with olefin over competing olefin side reactions such as polymerization. However, overall reaction rates decreases with decreasing temperatures. Temperatures within the given range, and preferably in the range from about 40F to about F, provide good selectivity for alkylation of isoparaffin with olefin at commercially attractive reaction rates.

Reaction pressures contemplated in the present invention are sufficient to maintain reactants in the liquid phase and may range from ambient to superatmospheric. Reactant hydrocarbons may be normally gaseous at alkylation reaction temperatures, thus reaction pressures in the range of about lOl50 psig are preferred. With all reactants in the liquid phase, increased pressure has no significant effect upon the alkylation reaction.

Contact times for hydrocarbon reactants in an alkylation zone, in the presence of the alkylation catalyst of the present invention may range from about 0.5 to about 60 minutes. Preferably, contact time is sufficient for essentially complete conversion of olefin reactant in the alkylation zone. In the alkylation process of the present invention, employing isoparaffin and olefin reactants in volume ratios in the range of 2:1 to 20:], wherein the alkylation reaction mixture comprises about 40-70 volume percent acid catalyst phase and about 60-30 volume percenet hydrocarbon phase, and

wherein good Contact of olefin with isoparaffin is maintained in the reaction zone, essentially complete conversion of olefin may be obtained at olefin space velocities in the range of about 0.1 to 1 volumes olefin per hour per volume catalyst (v/v/hr. Optimum space velocities will depend upon isoparaffin and olefin reactants, the particular compositions of alkylation catalyst,

and alkylation reaction conditions. Consequently, the

preferred contact times are sufficient for providing an olefin space velocity in the range of 0.1 to 1 (v/v/hr) and allowing essentially complete conversion of olefin reactant in the alkylation zone.

Batch or continuous methods of operation may be used. Different procedures, which may vary with the method of operation, may be used for ensuring the presence of acid catalyst having the desired acidity and ratio of H to HFSO in the reaction mixture. Thus, in batch operations, acid catalyst having the desired ratio of H 50 and HFSO and having an acidity in the higher range may be added with isoparaffin to a reaction vessel. Olefin reactant can then be added at a desired rate to the reaction mixture for a time until acidity of the acid catalyst declines, or until a substantial portion of the isoparaffin reactant is consumed.

In a continuous process, isoparaffin and acid catalyst are continuously charged separately to an alkylation zone maintained at alkylation reaction conditions. Olefin hydrocarbon may be separately charged, or may be added in admixture with the isoparaffin at a rate to maintain the desired olefin space velocity in the alkylation zone. Reaction effluent is continuously removed from the alkylation zone and separated into an acid phase and a hydrocarbon phase comprising unreacted isoparaffin and alkylate hydrocarbon. Separated acid phase is recycled for contact with additional hydrocarbon reactants. Preferably, the acid phase contains from 5 to 30 volume percent hydrocarbon for improving contact of isoparaffin with olefin in the presence of the acid catalyst. A portion of the acid phase may be continuously or intermittently withdrawn from the process for removal of water and acid oil impurities. Fresh acid catalyst, comprising H 50, and HFSO in the selected ratio and having high acidity is added to make up for the acid phase withdrawn, thereby maintaining the acidity of the acid catalyst in the alkylation zone within the desired range of acidity. The separated hydrocarbon phase may be fractionated in a fractionation zone into an alkylate fraction and an unreacted isoparaffm fraction. Additionally, hydrocarbon impurities, such as normal paraffins, may be fractionated from isoparaffins in the frationation zone. Preferably. fractional distillation methods are employed to fractionate the separated hydrocarbon phase. The isoparaffm fraction may be recycled to the alkylation zone for contact with additional reactants.

The desired agitation of the reaction mixture, for insuring good contact of isoparaffin with olefin in the alkylation zone. may be provided in a number of ways. For instance, mechanical mixers may be used for forming a reaction emulsion of hydrocarbon and acid cata- Catalyst phase for maintaining catalyst acidity at a pre selected value, and spent catalyst was withdrawn to maintain the catalyst volume in the system. 1

For alkylation runs employing H SO catalyst, fresh H 50 and 1.8 weight percent H O, which'results in 'a fresh catalyst having 0.172 to 1 weight ratio of fluoro-.

sulfonic acid to sulfuric acid and titratable acidity, of 21.53 meq/gm.

Operating conditions and results of this first series of alkylation runs, are set-out in Table l below. Butylene space velocities (volumes olefin per hour per volume catalyst) were maintained relatively constant, as were reaction temperatures and isobutane-to-butylene volume ratios. Acidity of the equilibrium mixed catalyst in the reaction zone varied over a narrow range lyst in the alkylation zone. Additionally, charge and rel7.318.2 meq/gm).

TABLE I Olefin lsoparaffin/ Acid Alkylatc Run Temp. Catalyst Acidity space velocity olefin Consumption Octane No. "F Type meq/gm \'/\'/hr. volume lb acid/ Clear ratio gal. allay. MON RON l Mixed 18.1 0. 1 6.26 0.75 93.4 95.7

HFSQ- H SO 2 50 Mixed 18. 0.19 6.26 0.86 93.2 95.6

arsoyn so,

3 50 Mixed 18.2 (1.17 6.26 1.01 93.3 95.6

HFSO;,-H .SO., U 4 50 Mixed 17.3 0.24 6.26 0.36 92.8 95.3

HFSO -H- SO. 5 50 Mixed 17.3 0. 1 6.26 0.30 92.5 95.0

HFSO -H SO, I 6 5O H SO, 18.4 0. 3 6.26 0.74 I 92.8 95.3 7 5t) H 50 18.4 0.2 6.26 0.80 92.3

cycle streams may be charged through nozzles or jets into the reaction zone for providing the desired agitation. These, and other methods for obtaining good liquid-liquid mixing in the alkylation zone may be used advantageously in the method of the present invention.

The following examples demonstrate 'the advantages of the present invention. These examples are by way of illustration only. and are not intended as limitations. upon the invention as set out in the appended claims.

EXAMPLE I Series of continuous alkylation runs were performed in the liquid phase, at about 50F, employing as reactant charge stocks a petroleum refinery butylene stream and technical grade isobutaneThe purpose of these runs was to compare alkylation reactions employing sulfuric acid catalyst with alkylation reactions employing the mixed H SO HFSO catalysts of the present invention. In all these alkylation runs, acid catalyst and reactant hydrocarbons were contacted in an alkylation reactor with mechanical mixing to form a reaction emulsion. Reaction emulsion was continuously withdrawn and separated, by gravity settling, into a cat alyst phase and a hydrocarbon phase. Separated catalyst phase was recycled to the alkylation reaction for contact with additional reactant hydrocarbons. Intermittently. fresh acid catalyst was added to the recycle From Table 1, comparison of Runs 1-3 with Runs 6 and 7, made at approximately the same catalyst acidity,

demonstrates that octane of alkylate produced employing the mixed HFSO H SO catalyst of the present invention is increased over octane of alkylate produced under similar conditions employing H catalyst. Comparison of runs 4 4and 5 with runs 6 and 7 demonstrates that in alkylation runs'operated to yield alkylates of about the same octane value, acid consumption when using catalyst of the present invention is about 1/2 the acid consumption when using H SO catalyst.

EXAMPLE II A second series of alkylation runs was mada employing the alkylation process of Example 1. Olefin space velocity, catalyst acidity, and isoparaffin to olefin ratio lyst comprised 14.3 weight percent HFSO 84.0 weight percent H 50 and 1.7 weight percent H O. Operating conditions and results of this second set of alkylation runs are set-out in Table ll, following.

TABLE 11 Catalyst Olefin lsoparaffin Acid Alkylate Alkylate Run Temp. Catalyst Acidity space velocity olefin Consumption Octane Octane No. F Type meq/gm \'/\'/hr. volume lb acid/ Clear Clear ratio gal. alky. MON RON 8 50 Mixed 18.0 0.22 6.73 0.47 94.0 96.4 9 50 Mixed 18.5 0.46 6.37 0.60 93.6 95.8 10 50 Mixed 18.1 0.47 5.51 0.43 940 96,3 11 50 Mixed 18.0 0.52 5.51 0.45 94.2 96.6 12 50 Mixed 17.5 0.42 5.51 0.22 93.2 95.5 13 50 Mixed 16.9 0.42 5.51 0.28 91.3 93.7 14 50 Mixed 18.0 0.57 6.73 0.38 93.2 95.7 15 50 Mixed 18.2 0.63 6.37 0.48 92.9 95.2 16 50 Mixed 18.0 0.77 6.73 0.21 92.3 94.6 17 50 Mixed 18.4 0.79 6.37 0.33 93.5 95.8 18 50 H- SO 18.5 0.21 6.73 0.52 93.1 95.7 19 50 H- .SO 18.4 0.43 5.51 0.45 91.8 94.3 20 5O H 50, 18.6 0.68 6.73 0.44 91.8 94.3 21 50 H SO, 18.5 0.79 6.03 0.42 91.6 94.1

a weight ratio of about 6/7.9. lsoparaffin comprised 20 technical grade .isobutane. Comparison runs, using H 50 as catalyst, are included in this series of alkylation runs. Fresh H 80 catalyst comprised 98.0% H 50 containing 2.0% water. Fresh H- ,SO HFSO comprised 14.3 weight percent HFSO 84.0 weight percent H 80 and 1.7 weight percent H O. Operating conditions and results of this series of runs are shown in Table III below.

TABLE III lsoparuffin/ Acid Alkylate Octane Olefin olefin Consumption Run Temp. Catalyst Acidity space velocity \olume lb acid/ No. "F Type meq/gm v/v/hr. ratio gal. alky MON RON (clear) (clear) 22 50 Mixed 17.9 0.19 5.46 053 91.1 93.2 23 50 Mixed 17.2 0.18 5.46 O 53 90.2 92.4 24 50 Mixed 17.3 0.17 5.46 039 90.8 93.1 25 50 H 50 18.8 0.23 5.46 l 04 90.8 93.2 26 50 H 50 18.4 0.24 5.46 0 81 90.5 92.8

sumption decreases significantly as catalyst acidity decreases from 18.1 to 17.5 meq/gm. However, in going from acidity of 17.5 to 16.9 meq/gm, alkylate octane deceases significantly, and acid consumption increases, indicating the olefin side reactions were becoming significant at the expense of desired alkylation reaction. However, at the catalyst acidity of 16.9 meq/gm, acid consumption is still significantly better than for alkylation with H SO alone (see run 19). Consequently, from these results, it appears H SO HFSO mixed catalyst systems are effective at catalyst acidities greater than about 16.5 meq/gm, and preferably in the range of about l7-l8.5 meq/gm.

EXAMPLE 111 A third series of alkylation runs was made employing the alkylation process of Example I to demonstrate the effectiveness of the process of the present invention for alkylating with mixtures of butylene and propylene olefins; space velocity, catalyst acidity and isoparaffin to olefin ratio were maintained about the same throughout this series of runs. The olefin charge stock comprised a refinery mixture of propylene and butylenes in From the comparative examples of Table 111 it is seen that, for alkylating is'oparaffin with mixed propylenebutylene olefins to yield alkylate of about the same octane value, acid consumption was significantly less when the H SO HFSO catalyst of the present invention was employed in the alkylation process, as compared to acid consumption when H catalyst was used.

EXAMPLE 1V TABLE IV TABLE IV-continued Isoparalfin/ Alkylatc Octane ()lefin olefin Run Temp. Catalyst space velocity \olumc No. F Type /\/hr. ratio MON RON 28 t) HClSO; (1.38 (3.9/1 92.5 94.7

H SO,

From Table IV, it can be seen that the HFSO;,H SO acid catalyst mixture of the present invention is superior to the HClSO;;-I-I SO mixture in catalyzing the alkylation of the isoparaffin with olefins. Both alkylate research and motor octane values are substantially higher when using the catalyst of the present invention.

Since both HFSO and HC1SO are very strong acids, an effort was made to determine why the difference in behavior occurred. Analysis of the two mixed acid systems revealed considerable differences in behavior between the two halo-sulfonic acids. In the analyses, chloride and fluoride concentrations were determined for fresh and spent acid catalysts, and these are set out in Table V, below.

TABLE V 25 Halide lon Halide Ion Time EXAMPLE V F "h C a C 2 f. 25 Elm?" 23:31:58 ,12, Alkylation runs were made to determine theopti- Theoretical Actual mum HFSO /I-I SO ratio for such a mixed acid catamg/gm mtg/gm "lg/gm hrs lyst. Such runs were continuous and operated accord- HFso,-H. ,so, 27.17 27.9 28.2 45 3O ing to the alkylation process of Example I. Operating HCISOfl HJSO. .06 8 conditions and results of these alkylation runs are shown in Table VI, following.

TABLE VI Fresh Fresh Spent Olefin lsoparaffin/ Acid Alkylatc Octane Run Temp. Catalyst Catalyst Catal st space velocity olefin Consumpi lion No. F HFSO weight ratio Acidity \'/\/hr. volume lb acid/ MON RON HFSOK/HZSO, nieq/gm ratio gal. alky (Clear) (Clcar) From Table V, it it seen that actual fluoride concen- From Table VI, it is seen that alkylate octane is maxitration of the fresh acid is, within experimental error, mum employing an alkylation catalyst comprising. the same as predicted by theory. Further, after 5O I-IFSO and I-I SO in a weight ratio of 0.17/1, correhours of running in the alkylation unit, the spent sponding to a fresh acid catalyst comprising 14.3 IIFSO --H SO contains the same fluoride concentra' weight percent HFSO 84% H and 1.7% 11 0. Adtion as the fresh acid. In contrast, the I-IClSO II SO ditionally, acid consumption was minimum using catafresh acid chloride concentration after mixing is only lyst having a 0.17/1 weight ratio of HFSO to H 50 32% of the theoretical chloride concentration (13.9 compared to catalyst compositions having both higher mg/gm actual chloride compared to 44.06 mg/gm theoand lower ratios of I-IFSO to H f I retical chloride). After running in the alkylation system It will be apparent to those skilled in the art that for about 8 hours, chloride concentration of the spent many variations and modifications of the present invenacid is essentially nil. At this point, the spent catalyst is 6 tion, which has as a principal feature the use of an acid no longer a mixed I-ICISO H SO acid system, but 0 catalyst comprising HFSO and H 50 in aweight ratio simply a sulfuric acid system. The loss of chloride is apof from about 0.1 l/l, to about 0.32/1 in a process for parently due to rapid reaction of HCISO with water to alkylating isoparaffin hydrocarbon with olefin hydroform HCl and H 50 The I-ICl leaves the acid catalyst carbon. as a gas, lowering the chloride concentration. This loss 68 I claim:

of HCl as a gas is observed upon adding HCISO to 97.8 weight percent H 50 whereupon rapid reaction with evolution of vapors, ensues at room temperatures. Water enters the alkylation process with the concentrated H SO and with hydrocarbon charge streams. During the alkylation reaction additional water is gen- I water to form HT and H 50 it does so to a lesser extent than HCISQ, under conditions existing in the alkylation process. Thus, mixed H SO HCISO cannot be effectively used in the process of the present invention due to the water present in the H 50 the olefin feed,

and as a product of side reactions. On the other hand, mixed HFSO I-I SO catalysts are not seriously af-' fected by the amount of water normally present in the alkylation processes.

1. In a liquid alkylation process for alkylating C C isoparaffms with C C mono-olefins to form alkylate I I hydrocarbon products; the improvement which com-. prises:

13 contacting. in an alkylation zone, isoparaffin and olefin reactants with a catalyst comprising HFSO and H 80, in a weight ratio of from about 0.11/1, to about 0.32/1, and having a titratable acidity of from about 16.5 to about 21 meq/gm.

2. The method of claim 1 wherein said acid catalyst comprises from about to about 3 weight percent H 0, and from about 0 to about weight percent acid oils, and wherein said acid catalyst has a titratable acidity of from about 16.5 to 18.5 meq/gm.

3. The method of claim 2 wherein said alkylation catalyst comprises HFSO and H 80, in a weight ratio of about 0. 17/1.

4. In a liquid phase alkylation process for alkylating isobutane with olefin hydrocarbons selected from the group consisting of propylene, butylene, and mixtures thereof for production of alkylate hydrocarbons useful as gasoline blending stocks; the improvement which comprises:

contacting, in an alkylation zone, isobutane with olefin reactants with an alkylation catalyst comprising HFSO and H 50, in a weight ratio of from about0.l l/l to about 0.32/1 respectively, and having a titratable acidity of from about 16.5 to about 21 meq/gm.

5. The method of claim 4 wherein said acid catalyst comprises from about 0 to about 3 weight percent H 0, and from about 0 to about 10 weight percent acid oils, and wherein the titratable acidity of said catalyst is from about 16.5 to about 18.5 meq/gm.

6. The method of claim 5 wherein said alkylation catalyst comprises HFSO and H 80 in a weight ratio of about 0.17/1.

7. In a liquid phase alkylation process wherein isobutane is alkylated with olefin hydrocarbons selected from the group consisting of propylene, butylenes and about 2/1 to about 20/1, at a temperature of from about 0F to about F under conditions of good mixing in the presence of a strong acid alkylation catalyst such that the reaction mixture comprises about 40-60 volume percent hydrocarbon phase and 60-40 volume percent acid phase; the improvement which comprises:

contacting isobutane and olefin reactants in the reaction zone at an olefin space velocity of from about 0.1 to about 1.0 volumes olefin per hour per volume catalyst with an acid catalyst comprising fluorosulfonic acid and sulfuric acid in a weight ratio offrom about 0.1 1/1 to about 0.32/1 and having a titratable acidity of from about 16.5 meq/gm to about 21 meq/gm.

8. The method of claim 7 wherein a reaction effluent from the reaction zone is separated in a separation zone into a hydrocarbon phase, comprising unreacted isoparaffin and alkylated hydrocarbon, and into an acid phase; wherein a major portion of the separated acid phase is recirculated to said reaction zone; wherein a minor portion of said catalyst phase is withdrawn as spent catalyst for removal of impurities and reaction by-products from the process, and wherein the volume of acid catalyst in the alkylation process is maintained by addition of a fresh acid mixture comprising about 88.7 to 74.5 weight percent sulfuric acid, about 9.5 to 24.0 weight percent fluorosulfonic acid and about 1.7 to 1.4 weight percent water.

9. The process according to claim 8 wherein the olefin space velocity in the reaction zone is in the range of from about 0.17 to about 0.79 volumes olefin per hour per volume catalyst; and wherein the titratable acidity of the acid alkylation catalyst is in the range of about 16.5 to about 18.5 milliequivalents per gram.

10. The process according to claim 9 wherein the weight ratio of fluorosulfonic to sulfuric acid in said UNITED STATES PATENT AND TRADEMARK OFFICE CERTIFICATE OF CORRECTION PATENT NO. 3,922,319

DATED November 25, 1975 |N\/ ENT()R(5) James W. Brockington It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown betow:

Claim 1, column 12, line 1, "In a liquid alkylation" should be In a liquid phase alkylation.

Signed and Sealed this T weary-sixth D a y of February 1980 [SEA L] Arrest:

SIDNEY A. DIAMOND Arresting Oflicer Commissioner of Patents and Trademarks 

1. IN A LIQUID ALKYLATION PROCESS FOR ALKYLATING C4-C6 ISOPARAFFINS WITH C3-C5 MONO-OLEFINS TO FORM ALKYLATE HYDROCARBON PRODUCTS; THE IMPROVEMENT WHICH COMPRISES; CONTACTING IN AN ALKYLATION ZONE, IS PARAFFIN AND OLEFIN REACTANTS WITH A CATALYST COMPRISING HFSO3 ND H2SO4 IN A WEIGHT RATIO OF FROM ABOUT 0.11/1, TO ABOUT 0.32/1 ABD HAVING A TITRATABLE ACIDITY OF FROM ABOUT 16.3 TO ABOUT 21 MEG/GM.
 2. The method of claim 1 wherein said acid catalyst comprises from about 0 to about 3 weight percent H2O, and from about 0 to about 10 weight percent acid oils, and wherein said acid catalyst has a titratable acidity of from about 16.5 to 18.5 meq/gm.
 3. The method of claim 2 wherein said alkylation catalyst comprises HFSO3 and H2SO4 in a weight ratio of about 0.17/1.
 4. In a liquid phase alkylation process for alkylating isobutane with olefin hydrocarbons selected from the group consisting of propylene, butylene, and mixtures thereof for production of alkylate hydrocarbons useful as gasoline blending stocks; the improvement which comprises: contacting, in an alkylation zone, isobutane with olefin reactants with an alkylation catalyst comprising HFSO3 and H2SO4 in a weight ratio of from about0.11/1 to about 0.32/1 respectively, and having a titratable acidity of from about 16.5 to about 21 meq/gm.
 5. The method of claim 4 wherein said acid catalyst comprises from about 0 to about 3 weight percent H2O, and from about 0 to about 10 weight percent acid oils, and wherein the titratable acidity of said catalyst is from about 16.5 to about 18.5 meq/gm.
 6. The method of claim 5 wherein said alkylation catalyst comprises HFSO3 and H2SO4 in a weight ratio of about 0.17/1.
 7. In a liquid phase alkylation process wherein isobutane is alkylated with olefin hydrocarbons selected from the group consisting of propylene, butylenes and mixtures thereof to form highly branched alkylate hydrocarbons suitable for use in gasoline, wherein isobutane and olefin reactants are contacted in a reaction zone, in a volume ratio of isobutane to olefin of from about 2/1 to about 20/1, at a temperature of from about 0*F to about 100*F under conditions of good mixing in the presence of a strong acid alkylation catalyst such that the reaction mixture comprises about 40-60 volume percent hydrocarbon phase and 60-40 volume percent acid phase; the improvement which comprises: contacting isobutane and olefin reactants in the reaction zone at an olefin space velocity of from about 0.1 to about 1.0 volumes olefin per hour per volume catalyst with an acid catalyst comprising fluorosulfonic acid and sulfuric acid in a weight ratio of from about 0.11/1 to about 0.32/1 and having a tiTratable acidity of from about 16.5 meq/gm to about 21 meq/gm.
 8. The method of claim 7 wherein a reaction effluent from the reaction zone is separated in a separation zone into a hydrocarbon phase, comprising unreacted isoparaffin and alkylated hydrocarbon, and into an acid phase; wherein a major portion of the separated acid phase is recirculated to said reaction zone; wherein a minor portion of said catalyst phase is withdrawn as spent catalyst for removal of impurities and reaction by-products from the process, and wherein the volume of acid catalyst in the alkylation process is maintained by addition of a fresh acid mixture comprising about 88.7 to 74.5 weight percent sulfuric acid, about 9.5 to 24.0 weight percent fluorosulfonic acid and about 1.7 to 1.4 weight percent water.
 9. The process according to claim 8 wherein the olefin space velocity in the reaction zone is in the range of from about 0.17 to about 0.79 volumes olefin per hour per volume catalyst; and wherein the titratable acidity of the acid alkylation catalyst is in the range of about 16.5 to about 18.5 milliequivalents per gram.
 10. The process according to claim 9 wherein the weight ratio of fluorosulfonic to sulfuric acid in said fresh catalyst is about 0.17/1. 